"The future of ceramics appears bright as the fusion of innovative science and engineering continues to advance," says Cheryl Xu, professor at NC State. Researchers at North Carolina State University unveiled a groundbreaking laser sintering technique for creating ultra-high temperature ceramics on May 14, 2025.
The new method significantly streamlines the production of ceramics like hafnium carbide (HfC), known for its exceptional heat resistance. Traditional methods require temperatures exceeding 2,200 degrees Celsius, but the laser technique is faster and more energy-efficient.
The process involves directing a 120-watt laser at a liquid polymer precursor in a controlled environment. This converts the liquid into a solid ceramic material, suitable for coatings or 3D-printed structures. The laser sintering technique is also portable, unlike traditional sintering.
One key application is creating protective coatings for carbon composites used in hypersonic technologies. The localized laser sintering minimizes structural damage and enhances thermal protection. The technique also integrates with additive manufacturing, enabling the creation of complex 3D ceramic structures.
The laser technique boasts a conversion efficiency of at least 50%, significantly higher than the 20-40% of traditional methods. This leads to less waste and a more sustainable manufacturing approach. The team successfully produced crystalline, phase-pure HfC, demonstrating the technology's potential for extreme environments.
Tests on HfC coatings applied to carbon-fiber composites showed strong adhesion and uniform coverage, essential for thermal protection systems. This opens doors for enhanced engineering applications in aerospace and other industries. The research, published in the Journal of the American Ceramic Society, hopes to inspire further adoption of these techniques.